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Book Chapter
Design of Experiments
Available to PurchaseBook: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780171
EISBN: 978-1-62708-268-6
... is necessary to confirm or rule out suspected causes. This chapter discusses two predominant methods for doing this, namely analysis of variance (ANOVA) and Taguchi methods (a more powerful technique based on ANOVA). analysis of variance design of experiments failure causes failure mode assessment...
Abstract
After the failure analysis team hypothesizes failure causes, prepares a failure mode assessment and assignment, and evaluates all potential failure causes, it may find in some cases that several causes are still suspect but cannot be confirmed. In this situation, an experiment is necessary to confirm or rule out suspected causes. This chapter discusses two predominant methods for doing this, namely analysis of variance (ANOVA) and Taguchi methods (a more powerful technique based on ANOVA).
Image
Flow diagram of a design of experiments prepared to optimize die design. FE...
Available to PurchasePublished: 30 April 2025
Fig. 4.37 Flow diagram of a design of experiments prepared to optimize die design. FEM, finite-element method; QA, quality assurance; CAD, computer-aided design
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Image
The Taguchi design of experiments process selects factors and their interac...
Available to PurchasePublished: 01 December 2009
Fig. 17.4 The Taguchi design of experiments process selects factors and their interactions, develops an appropriate experimental design, analyzes results using the analysis of variance technique, and concludes with a confirmation experiment.
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Image
Flow diagram of a design of experiments prepared to optimize die life. FEM,...
Available to PurchasePublished: 30 April 2025
Fig. 4.39 Flow diagram of a design of experiments prepared to optimize die life. FEM, finite-element method; QA, quality assurance
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Image
Proposed design of experiments flow diagram of scrap optimization in a char...
Available to PurchasePublished: 30 April 2025
Image
Design of experiments flow diagram to develop new production practices. QA,...
Available to PurchasePublished: 30 April 2025
Fig. 6.28 Design of experiments flow diagram to develop new production practices. QA, quality assurance
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Design of experiments (DOE) flow diagram to optimize extrusion speed to com...
Available to PurchasePublished: 30 April 2025
Fig. 6.29 Design of experiments (DOE) flow diagram to optimize extrusion speed to compare productivity
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Book Chapter
Extrusion of Soft- and Medium-Grade Alloys
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 30 April 2025
DOI: 10.31399/asm.tb.aet2.t59420233
EISBN: 978-1-62708-487-1
... of experiments (DOE) for the aluminum extrusion plant to improve overall productivity. It also focuses on heat treatment of aluminum alloys. aluminum aluminum alloys billets casting design of experiments extrusion extrusion die melting precipitation hardening solution heat treatment EXTRUSION...
Abstract
This chapter discusses the extrusion technology of soft- and medium-strength aluminum alloys. The relative extrudability ratings of some soft- and medium-grade alloys are given. The chapter presents useful extrusion parameters and their relationships associated with day-to-day production practices in the aluminum extrusion industry. Useful parameters discussed include: extrusion runout; extrusion pressure; ram or extrusion speed control; and butt or extrusion discard thickness control. The chapter provides fundamental approaches to introducing and developing the design of experiments (DOE) for the aluminum extrusion plant to improve overall productivity. It also focuses on heat treatment of aluminum alloys.
Book Chapter
Post-Failure-Analysis Activities
Available to PurchaseBook: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780189
EISBN: 978-1-62708-268-6
...” technique, or fault-tree analysis. List each potential failure cause in a failure mode assessment and assignment. Use appropriate documentation reviews, interviews, design analyses, hardware analyses, and designed experiments to converge on the root cause. Identify potential interim and long-term...
Abstract
At the conclusion of a systems failure analysis, the people involved should have a much more in-depth understanding of how the system is supposed to work. The analysis should help understand shortfalls in the design, production, testing, and use of the system. The failure analysis team will have identified other potential failure causes and actions required to preclude future failures. This is valuable knowledge, and it should not be set aside or ignored when the failure analysis team concludes its activities. This chapter is a brief account of the creation of failure analysis libraries, of process guidelines based on previous failure analyses, and of troubleshooting and repair guidelines. Also provided is a listing of the various steps that should be included in a failure analysis procedure.
Book Chapter
Quality Control and Quality Assurance
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 1995
DOI: 10.31399/asm.tb.sch6.t68200220
EISBN: 978-1-62708-354-6
... that is being used by steel foundries to improve quality by improving the process is the use of designed experiment techniques. Rather than making changes to the process in an intuitive, on line way, this method allows changes to be tested off line in a planned, statistically valid way. Several variables can...
Abstract
Casting quality and consistency need to be carefully controlled. This chapter discusses the procedures that describe the process and product quality controls. In addition, it provides information on quality assurance programs.
Book Chapter
Statistical Process and Quality Control
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 March 2000
DOI: 10.31399/asm.tb.aet.t68260233
EISBN: 978-1-62708-336-2
... of substantial quality, cost, and productivity improvements in the organization. At the highest levels of maturity, companies use design of experiments and statistical process control methods extensively and make relatively modest use of acceptance sampling. The introduction of statistical process controls helps...
Abstract
This chapter provides an introduction to statistical process control and the concept of total quality management. It begins with a review of quality improvement efforts in the extrusion industry and the considerations involved in developing sampling plans and interpreting control charts. It then lays out the steps that would be followed in order to implement statistical testing for billet casting, die performance, or any other process or variable that impacts extrusion quality. The chapter concludes with an overview of the fundamentals of total quality management.
Book Chapter
Reliability and Quality Basics for Failure Analysts
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2019
DOI: 10.31399/asm.tb.mfadr7.t91110666
EISBN: 978-1-62708-247-1
... Abstract This chapter surveys both basic quality and basic reliability concepts as an introduction to the failure analysis professional. It begins with a section describing the distinction between quality and reliability and moves on to provide an overview of the concept of experiment design...
Abstract
This chapter surveys both basic quality and basic reliability concepts as an introduction to the failure analysis professional. It begins with a section describing the distinction between quality and reliability and moves on to provide an overview of the concept of experiment design along with an example. The chapter then discusses the purposes of reliability engineering and introduces four basic statistical distribution functions useful in reliability engineering, namely normal, lognormal, exponential, and Weibull. It also provides information on three fundamental acceleration models used by reliability engineers: Arrhenius, Eyring, and power law models. The chapter concludes with information on failure rates and mechanisms and the two techniques for uncovering reliability issues, namely burn-in and outlier screening.
Book Chapter
Systems Failure Analysis Introduction
Available to PurchaseBook: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780001
EISBN: 978-1-62708-268-6
..., and designed experiments to converge on the root cause. Identify potential interim and long-term corrective actions, and select the most appropriate corrective actions. Ensure corrective actions are implemented in all relevant areas (suppliers, inventory, work in progress, repair centers, and fielded...
Abstract
This chapter focuses on what can cause a system to fail and addresses the challenge in approaching a system failure. It then examines the steps involved in the four-step problem-solving process: defining the problem, identifying all potential failure causes and evaluating the likelihood of each, identifying the potential solutions, and identifying the best solution. The chapter concludes by describing the responsibilities of a failure analysis team.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2012
DOI: 10.31399/asm.tb.smfpa.t53500073
EISBN: 978-1-62708-317-1
... design for a new part generally is based on experience and knowledge gained from producing similar parts and necessary prototype runs. This experience-based methodology requires extensive resources and increases the design lead time. There are several articles and books that summarize the basic practical...
Abstract
This chapter presents two case studies; one demonstrating the use of finite-element analysis (FEA) in the design of a progressive die forming operation, the other explaining how software simulations helped engineers reduce thinning and eliminate cracking and deformation observed in clutch hubs formed using a three-step transfer die process. It also discusses the role of FEA and commercial software in the design of progressive dies.
Book Chapter
Design Analysis
Available to PurchaseBook: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780147
EISBN: 978-1-62708-268-6
... on the latter possibility. Based on the author’s experience, many people (especially the system designers) may be reluctant to conclude that designs can be defective. This is perhaps a natural reaction and explains why a first reaction is to find a nonconforming part or to conclude that the system...
Abstract
In some cases, the failure analysis team finds that all components meet their requirements, the system was properly assembled, and it was not operated or tested in an out-of-specification manner, yet it still failed. When this occurs, the only conclusion the failure analysis team can reach is that it missed something in its analysis or that the design is defective. This chapter focuses on the latter possibility by discussing the various factors that a failure analysis team should consider to identify the causes of defects in system design. These include requirements identification and verification, circuit performance, mechanical failures, materials compatibility, and environmental factors. Examples that illustrate the value of design analysis are also presented.
Book Chapter
Why Perform Failure Analysis?
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 30 November 2013
DOI: 10.31399/asm.tb.uhcf3.t53630xvi
EISBN: 978-1-62708-270-9
... Abstract Designs and materials continue to become more complex, with novel technologies developed to create them, and novel instruments invented to analyze them. Engineers at all stages of the design and manufacturing process should appreciate the reasons why formal failure analysis...
Abstract
Designs and materials continue to become more complex, with novel technologies developed to create them, and novel instruments invented to analyze them. Engineers at all stages of the design and manufacturing process should appreciate the reasons why formal failure analysis is performed. This chapter describes why failure analysis is conducted and outlines the responsibilities of the failure analyst.
Book Chapter
Selection of Heat Treat Process for Optimum Gear Design
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 2000
DOI: 10.31399/asm.tb.htgpge.t67320185
EISBN: 978-1-62708-347-8
... and the metallurgist is essential during the gear design process rather than after the gears are in production and rejections are occurring in heat treatment or failures in service. For years, material selection has been based on prior experience or some trial-and-error methods. A background of materials science...
Abstract
The successful design and manufacture of gears are influenced largely by design requirements, material selection, and proper heat treatment. This chapter addresses the cost factors and tradeoffs involved in selecting a material, design features, and a heat treating process to optimize gear performance for a particular application.
Book Chapter
Process Control in the Aluminum Extrusion Plant
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 March 2000
DOI: 10.31399/asm.tb.aet.t68260213
EISBN: 978-1-62708-336-2
... or to determine new process parameters of a particular product shape of a particular alloy. Using this system, an experiment can be done with different die designs to discover the best design to achieve high productivity and quality of extrusion. References References 1. Saha P. K. , Process...
Abstract
This chapter provides guidelines on how to set up and run an effective quality-improvement program for aluminum extrusion operations. It begins by identifying production processes and variables that impact the quality of hard and soft alloy extrusions. It then presents a series of checklists and flowcharts that can be used to monitor and troubleshoot billet-making and extrusion processes, die construction, equipment maintenance, heat treating, and sawing and stretching procedures. It also discusses the importance of charting test results and monitoring surface treatments that may be required to improve corrosion, oxidation, or wear resistance.
Book Chapter
Design Guidelines for Reduced Vibration
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 31 March 2024
DOI: 10.31399/asm.tb.gvar.t59360121
EISBN: 978-1-62708-435-2
... are based on the author’s many years of experience in designing both high-speed and low-speed gearboxes for reduced vibrations. General Recommendations The most opportune time to consider design improvements for reduction of vibration and noise of a gearbox is at the design stage. Proper selection...
Abstract
This chapter presents guidelines for reducing gearbox vibration, with an emphasis on design factors that play major roles in influencing vibration.
Book Chapter
Test Specimen Drawings
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140301
EISBN: 978-1-62708-335-5
... are of the same magnitude. The notched rotating beam fatigue specimens were similar to the smooth specimens, but contained a sharp V-notch in the center of the test section, providing a theoretical stress concentration factor ≥ 19. Rotating beam specimens with slight variations in design are presented. Figure...
Abstract
This appendix contains drawings that illustrate the test specimens used in generating the data related to aluminum alloy castings.
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